Design and Simulation of A PLC Based Speed Controlled Color

Sorting System
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Eng. Kalyankolo Umaru , Munguleni Marlon

Department of Electrical and Control Engineering, International University of East Africa, Uganda
1 2
[email protected] ,[email protected]

Abstract: For simulation purposes in Factory IO and TIA Portal, the project is tailored to emulate
industrial sorting operations. In numerous industrial scenarios, sorting operations play a crucial role,
with objects segregated based on various criteria such as dimensions, colors, weight, and material
composition. For instance, within Thermal Power Stations, electromagnetic sorting techniques are
employed to separate ferromagnetic materials from coal. This project specifically focuses on sorting
goods based on color, with adjustable speed parameters to match production rates. The system is
equipped with a digital display screen, providing real-time feedback on the count of sorted objects, and
receives an analog speed signal from the PLC for precise control. This project is divided into two primary
components:
Software: The software aspect involves the implementation of ladder logic programming in TIA Portal,
enabling systematic control of the entire project process based on the input data sequence.
Simulation in Factory IO: This encompasses the virtual representation of conveyors for object
transportation and RGB color vision sensors for color detection. The entry conveyor features two
branches to load objects onto the respective conveyors, directed by the sorting logic implemented in TIA
Portal.

Keywords; Programmable Logic Controller (PLC), Factory IO, TIA portal, Red, Green and Blue (RGB),
Digital display screen.

1. Introduction
The color sorting machine is a sophisticated piece of equipment designed to automate the process of
sorting objects based on their color. These machines are commonly used in various industries such as
food processing, agriculture, recycling, and manufacturing to improve efficiency, accuracy, and
consistency in sorting tasks [1], [3]. The concept of color sorting dates back to the early 20th century
when manual sorting methods were predominant in industries such as agriculture and manufacturing
[11], [12]. With the advancement of technology, particularly in optics and computing, automated color-
sorting machines began to emerge in the mid-20th century [12]. Early models were rudimentary and
primarily used in specific industries such as food processing and textile manufacturing. Color sorting
machines work based on the principles of optical sensing and image processing. A conveyor belt or
chute system feeds objects to be sorted into the machine's inspection area. A high-resolution camera
captures images of the objects as they pass through. Advanced image processing algorithms analyze the
images to identify the color of each object accurately. Based on predefined criteria, the machine
activates pneumatic or mechanical mechanisms to divert objects into appropriate bins or channels. This
project therefore, is intended to constitute a real time application which sorts objects by color with a
controllable speed using a PLC [1]. The system attains efficient connection between the objects using
several sensors [1]. The modules used with PLC for this system are, RGB color vision sensors for color
detection, a potentiometer used to vary an analog voltage of 0 to 10V for speed control of the conveyor,
a pivot sorter arm for sorting the objects, digital display screen to display the number of sorted goods
and analog speed signals, Red and Green stack lights to show the off and on state of the system
respectively.

1.1 Aim and Objective

 To Programme a color vision sensor and pivot arm sorter in the ladder logic to achieve color sorting.
 To integrate a module so as to control supply voltage frequency to achieve a variable speed.
 To Programme a counter in the ladder logic to count the number of sorted goods.

2. Literature review
The project aims to boost sorting efficiency by implementing speed control mechanisms, adjusting
conveyor speeds according to production rates, as mentioned in research papers such as "Design and
Development of a PLC Based Automatic Object Sorting" and "Design and Fabrication of Automated

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Sorting System." Furthermore, it seeks to automate the counting of sorted goods using counters, in line
with suggestions from "Image Processing Based Automatic Color Object Sorting Using PLC System" to
enhance accuracy and productivity.
The tri stimulus theory of color perception
Human color perception is trichromatic, based on stimulation of three types of cone cells: short (S),
medium (M), and long (L) wavelengths, corresponding to blue, green, and red.
Color model
As Stephanie, (2018) mentioned, a color model is a method that uses three primary colors to generate a
larger range of colors. There are several types of color models used for several aims, and each has a
slightly different range of colors they can create. The whole range of colors that a definite type of color
model creates is called a color space [1]. All color results from how our eye procedures light waves, but
reliant on the type of media, creating that color comes from several methods.

The RGB color model

Two primary color models exist, with the most prevalent being the Red/Green/Blue (RGB) model utilized
in digital media, harnessing light to produce color. RGB, also known as an additive color model,
generates white when its three primary colors are displayed at equal intensity, and black when all lights
are off. In an RGB image, each primary color (red, green, blue) comprises an independent image plane,
with specific colors determined by the volume of each primary component [1],[10]. This model employs
additive mixing of red, green, and blue to create secondary colors like yellow (red + green), cyan (blue +
green), magenta (red + blue), and white (red + green + blue)

Figure 1 RGB Color Model Stephanie,(2018)

3. Methodology
The methodological steps involved in the project execution are as follows;
The project architecture

Figure 1 Project Architecture

Entry belt conveyor (6meters) labelled 1: The production line, this facilitates the movement of the
objects.
Two pivot arm sorters labelled 4 and 5: Their purpose is to push the objects for sorting.
Two (2meter) conveyors labelled 2 and 8: conveys the sorted objects to their destination.
Color Vision sensor labelled 10: This sensor is programmed to detect both blue and green object. It’s
responsible for the operation of pivot sorter arms 4 and 5 depending on the color detected.
The exit color vision sensor labelled 3: This sensor is specifically programmed to detect a blue colored
object, its purpose is to reset the pivot arm sorter labelled 4 and also the plc.’s memory for the color
vision sensor labelled 10 for blue detection.
The exit color vision sensor labelled 6: This sensor serves the same purpose to that of 3, it’s only
programmed to sense a green colored object, and its purpose is to reset
The pivot arm sorter labelled 5 and also the plc.’s memory for the color vision sensor labelled 10 for
green detection.
The project flow chart for Sorting

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Figure 2: Sorting flow chart

To operate the system, it begins with initialization steps where all components are initialized, including
the central color vision sensor, pivot arm sorters, and potentiometer signal. Once initialized, the system
enters a main loop where it continuously monitors the central color vision sensor and other
components.
Within the main loop, the system checks the value of the central color vision sensor. If the value is 4,
indicating the presence of blue color, the system activates pivot arm sorter 1. Similarly, if the value is 1,
indicating the presence of green color, the system activates pivot arm sorter 2.
Alongside sorting based on color, the system also adjusts the speed of the sorting system based on the
potentiometer signal to ensure efficient operation. This cycle is continuous and the flow chart is shown
in the figure 3 above.
The programmable logic controller

A programmable logic controller (PLC) is an electronic system that can be programmed to control
various machines or processes. It stores user-created instructions in its memory, allowing it to perform
tasks like logic operations, sequencing, timing, counting, and arithmetic. PLCs can handle both digital
and analog inputs and outputs.
Unlike older relay-based systems, PLCs offer more flexibility and advanced logic capabilities, making
them versatile tools in industrial automation. SIEMENS is a notable brand known for producing high-
performance automation devices, including PLCs, widely used across different industries for their
reliability and adaptability.
Programming in PLC

In this project, the PLC utilizes the Siemens Tia portal (Totally Integrated Automation Software) for
programming purposes. This software provides a platform for users to input programs into the PLC.
Before the PLC can execute any control tasks, it needs to be programmed accordingly.
Siemens Tia portal supports multiple programming languages, including:
Ladder Language (LD): This language uses graphical symbols resembling ladder rungs to represent logic
functions. It's commonly used in PLC programming due to its ease of understanding, especially for those
familiar with electrical schematics.
Function Block Diagram: This language employs graphical blocks to represent functions and their
interconnections. It's useful for creating modular and reusable code, particularly for complex systems.
Sequential Flow Chart (SFC): SFC is a graphical language that represents the sequence of steps in a
process. It's beneficial for visualizing and designing sequential control logic.
Structured Text Language (STL): This text-based language resembles traditional programming languages
like C or Pascal. It's suitable for implementing complex algorithms and mathematical operations.

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Ladder Logic

Indeed, ladder logic is extensively utilized in PLC programming, especially in scenarios necessitating
sequential control of processes or manufacturing operations. It is a graphical programming language
that mirrors relay diagrams, making it well-suited for translating traditional relay-based control systems
into PLC logic. Ladder logic is particularly effective for combinational processing.
The language employs fundamental graphic symbols such as contacts, coils, and blocks to represent
various components and operations within a control system. Contacts symbolize inputs or conditions,
while coils represent outputs or actions. Blocks, on the other hand, encapsulate sets of instructions or
logic operations.
Ladder logic allows for the execution of specific calculations and operations within these blocks,
enabling complex control tasks to be implemented efficiently. Furthermore, any necessary modifications
or adjustments to the control tasks can be made by simply altering the program, providing flexibility and
ease of maintenance.
Overall, ladder logic's intuitive graphical representation, its ability to handle sequential control tasks,
and its suitability for combinational processing make it a preferred choice for PLC programming in a
wide range of industrial applications.
3.1 PLC System Architecture

The system is comprised of several functional units essential for industrial automation, including color
vision sensors, exit color vision sensors 1 and 2, conveyor belts, pivot arm sorters, stack lights, digital
displays, and potentiometers. At the core of this system is the PLC (Programmable Logic Controller),
which serves as its central control unit.

Figure 3: PLC Architecture

3.1.2 Description of the proposed system

The project involves designing and simulating a PLC-based speed-controlled automatic color sorting
system, which is divided into six cycles or modules. Speed control module, object counting module,
system state indicators (Red and Green stack lights), object detection, object placement on conveyor
belt and conveyor starting, sensory detection, and sorting mechanism.
By incorporating controllable speed adjustment and automated object counting into the sorting
machine, the project aims to enhance efficiency, accuracy, and ease of operation. These features not
only improve the sorting process but also streamline record-keeping, reducing manual effort and
potential errors.
3.1.3 Object placing module (Emitter)

The emitter serves as the mechanism responsible for moving objects between workstations within the
sorting machine. In real world scenario, emitter emulates the robotic arm for object placement onto a
conveyor. Its function is to transfer objects from one station to another based on predefined criteria,
such as material type or other properties. In the context of Factory I/O simulation, the emitter module is
simulated to release objects onto the conveyor belt or another transport mechanism, ensuring they are
directed to the appropriate workstation for further processing or sorting.

3.1.4 PLC module (Siemen’s PLCSIM)

The PLC module consists of the following;

 Simatic S7-1200
 24v DC power module

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  Digital input modules
 Digital output modules
 4 Analog inputs
 8 Analog out puts.

3.1.4.1 Siemen’s PLC simulator

Figure 4 Siemen’s PLC Simulator

The Siemens S7-1200 is a popular PLC (Programmable Logic Controller) used in industrial automation
applications. Overall, the Siemens S7-1200 PLCs offer a combination of performance, flexibility, and
scalability, making them well-suited for a wide range of industrial automation applications. In my
project, its virtual form was used as the controller.

3.1.5 Conveyor Belt Module

The project comprises an entry belt conveyor that transports objects to pivot arm sorters for separation
and simultaneous sensing. The objects are sorted during this process. A conveyor named “blue belt
conveyor” is designated for transporting blue sorted objects to their respective destination, while a
conveyor named “a green belt conveyor” is allocated for carrying green sorted objects to their final
destination.

3.1.6 Object pushing Module

In this module, the pivot arm sorter receives sorting signals from the color vision sensor based on the
detected color. For instance, when a blue object is detected, pivot arm sorter 1, programmed for blue
objects, and is activated. Similarly, when a green object is detected, pivot arm sorter 2 is activated.

3.1.7 Sensor Module

In this project, three color vision sensors were employed: the central color vision sensor, exit color vision
sensor 1, and exit color vision sensor 2. The central vision sensor is configured to detect blue and green
colored objects, thereby enabling it to activate the respective pivot sorter arms.

4 Test Results

4.1 System Overview

4.2 Counting the number of sorted objects

The figure below illustrates the counting process for the sorted objects. From the visual representation,
it's evident that a total of eleven blue objects have been counted, with three green objects as well.

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4.3 Speed control analog signal of (5.7volts) simulation

The figure below shows the analog speed signal for the control of the conveyor belts .

4.4 Speed control analog signal of (10 volts) simulation

Analog speed signal of 10 volts shown for each of the three conveyors on their respective display
screens

4.6 Detailed discussion of the results

In the simulation of the PLC-based speed-controlled color sorting system, integration of TIA Portal and
Factory IO was seamlessly achieved, enabling a comprehensive simulation environment. The PLC logic
was effectively programmed to interpret the voltage signal from the potentiometer, ranging from 0 to
10 volts, which was utilized to control the speed of the conveyor belt. This integration provided dynamic
control over the system's speed, enhancing its adaptability and functionality.
During real-time simulation within the Factory IO environment, the color detection and sorting process
operated smoothly. Objects were accurately sorted based on predefined color criteria, demonstrating

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the reliability of the system. Performance analysis revealed satisfactory results in terms of speed
accuracy, color detection reliability, and overall sorting efficiency.
In discussions regarding the efficiency of PLC programming, the implemented logic for interpreting the
potentiometer signal and controlling conveyor belt speed was evaluated. The simplicity and robustness
of the programming logic were considered, along with potential areas for improvement or optimization.
Additionally, the accuracy of color detection algorithms and sensors was assessed. Challenges
encountered in accurately identifying different colors were discussed, along with possible
enhancements to improve detection accuracy.
Evaluation of the conveyor belt speed control mechanism highlighted its effectiveness in adapting to
varying color detection scenarios.
Seamless integration between TIA Portal and Factory IO was a notable aspect of the project. The ease of
simulation setup and data exchange between the software platforms facilitated a cohesive and realistic
simulation environment.
Looking to the future, opportunities for improvement include refining color detection algorithms,
optimizing PLC logic for enhanced speed control, and exploring alternative simulation software to
leverage advanced features and capabilities. These enhancements aim to further optimize the system
for real-world implementation, ensuring its effectiveness and reliability in industrial automation
scenarios.

5. Future scope
There are several improvements that can be made to the system to boost production rates and refine its
overall model. These enhancements involve both adjustments to the program and upgrades to the
components. For instance;
 We can implement the simulation into the real world.
 We can add a load cell for measurement and control of the product's weight.
 The system can be used as a quality controller by adding more sensors.
 The sensor can be changed according to the type of the product.
5.1 Conclusion

The simulation of the PLC-based speed-controlled color sorting system, integrating the potentiometer
speed signal and stack lights to indicate system states, along with the use of counters in ladder logic to
tally sorted objects, exemplifies the feasibility and efficacy of leveraging TIA Portal and Factory IO in
industrial automation applications.
The system's dynamic control over conveyor belt speed, combined with robust color detection and
sorting capabilities, highlights its promise for practical deployment in real-world scenarios.
The findings and discussions offer invaluable insights for ongoing refinement and optimization efforts,
laying the groundwork for heightened performance and expanded functionality in industrial automation
systems.

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